Water Pinch (Full)

Water Pinch Analysis
Dominic FOO, PhD, PEng

Dept of Chem & Env Eng
University of Nottingham Malaysia
About myself
Current position: Associate Professor (University
Nottingham Malaysia Campus)

Qualifications:
BEng (Chemical) (Hons.) (UTM)
MEng (Chemical) (UTM)
PhD (Chemical Engineering) (UTM)
Areas of work:
Research (material recovery, process design &
integration)
Education (undergraduate/post graduate/ profession
training)
Advice for career & professional development
Copyright@Dominic Foo
Pinch Analysis for Water Recovery
Talk outline
Domestic & industrial water usage
Water pinch analysis
Graphical targeting for water reuse/recycle
Nearest neighbour algorithm for network design
Algebraic targeting for water reuse/recycle &
regeneration
Conclusion
Residential water use
Water usage in our daily life

Hand washing
Shower
(2 minutes, 18 Litres)
Teeth brushing
Flower watering
(Sin Chew Jit Pow, 8 Oct 2003)
Water usage in our daily life

Car wash (with host)
Washing plates
Washing machine
Toilet flushing
(2 days once, 130 Litres)
(13.5 Litres / flush)
(Sin Chew Jit Pow, 8 Oct 2003)
Water use in process plant
(Smith, 2005)
Conventional water network

20.0 t/h
30.0 t/h
Process 1
Process 2
Fresh water
112.5 t/h
Wastewater
37.5 t/h
5.0 t/h
112.5 t/h
Process 3
Process 4
Better water utilisation schemes

Process 1
Process 1
Process 2
Reuse
Recycle
Process 1
Process 1
Regeneration
Regeneration
Process 2
Process 2
Regeneration-reuse
Regeneration-recycling
(Wang & Smith, 1994, 1995)
Limiting composite curve

C (ppm)
800
Process 4
Process 3
456
400
Process 2
100
50
Process 1
2
37 41
m (kg/h)
10
Mass transfer-based operation

Washing
Vessel
Water for
vessel
washing
Absorption
Wastewater
generated from
washing process
Sweet gas
Water
Sour gas
Sour water for
regeneration
11
Non-mass transfer processes

Utility make-up & blowdown
Cooling
tower makeup water
Cooling
tower
Boiler
Boiler
blowdown
Reactant & by-product formation

O2
C6H5NO2
Fe
H2O
C6H5NH2 +
Fe3O4
Aniline production
NH3
AN + H2O
C3H6
Acrylonitrile production
12
An Acrylonitrile AN Plant
5.0 kg AN/s
5.1 kg H2O/s
+ Gases
O2
NH3
C3H6
Water
6.0 kg H2O/s
BFW
1.2 kg H2O/s
Scrubber
Reactor
Off-Gas
Condensate
14 ppm NH3
0.4 kg AN/s
4.6 kg H2O/s
Boiler
Steam-jet
Ejector
Condensate
Steam
34 ppm NH3
0.2 kg AN/s
1.2 kg H2O/s
Tail gases
to disposal
18 ppm NH3
4.6 kg AN/s
6.5 kg H2O/s
10 ppm NH3
4.2 kg AN/s
1.0 kg H2O/s Distillation
Column
Decanter
Aqueous
layer
25 ppm NH3
0.4 kg AN/s
5.5 kg H2O/s
1 ppm NH3
3.9 kg AN/s
0.3 kg H2O/s
AN to
sales
Bottoms
0 ppm NH3
0.1 kg AN/s
0.7 kg H2O/s
20 ppm NH3
1.1 kg AN/s
12.0 kg H2O/s
Wastewater to Biotreatment
13
A poor recycle
5.0 kg AN/s
5.1 kg H2O/s
+ Gases
O2
NH3
C3H6
Water
6.0 kg H2O/s
BFW
1.2 kg H2O/s
Scrubber
Reactor
Off-Gas
Condensate
14 ppm NH3
0.4 kg AN/s
4.6 kg H2O/s
Boiler
Steam-jet
Ejector
Condensate
Steam
34 ppm NH3
0.2 kg AN/s
1.2 kg H2O/s
Tail gases
to disposal
18 ppm NH3
4.6 kg AN/s
6.5 kg H2O/s
10 ppm NH3
4.2 kg AN/s
Column
Decanter
Aqueous
layer
25 ppm NH3
0.4 kg AN/s
5.5 kg H2O/s
1 ppm NH3
3.9 kg AN/s
0.3 kg H2O/s
AN to
sales
Bottoms
0 ppm NH3
0.1 kg AN/s
0.7 kg H2O/s
20 ppm NH3
1.1 kg AN/s
12.0 kg H2O/s
14
FW elimination in scrubber ?
5.0 kg AN/s
5.1 kg H2O/s
+ Gases
O2
NH3
C3H6
Water
6.0 kg H2O/s
BFW
1.2 kg H2O/s
Scrubber
Reactor
Off-Gas
Condensate
14 ppm NH3
0.4 kg AN/s
4.6 kg H2O/s
Boiler
Steam-jet
Ejector
Condensate
Steam
Tail gases
to disposal
18 ppm NH3
4.6 kg AN/s
6.5 kg H2O/s
10 ppm NH3
4.2 kg AN/s
Column
Decanter
Aqueous
layer
25 ppm NH3
0.4 kg AN/s
5.5 kg H2O/s
34 ppm NH3
0.2 kg AN/s
1.2 kg H2O/s
1 ppm NH3
3.9 kg AN/s
0.3 kg H2O/s
AN to
sales
Bottoms
0 ppm NH3
0.1 kg AN/s
0.7 kg H2O/s
20 ppm NH3
1.1 kg AN/s
12.0 kg H2O/s
15
FW elimination in the boiler?

5.0 kg AN/s
5.1 kg H2O/s
+ Gases
O2
NH3
C3H6
Reactor
Off-Gas
Condensate
14 ppm NH3
0.4 kg AN/s
4.6 kg H2O/s
Steam-jet
Ejector
BFW
Water
Condensate
Steam
1.2
kg
H
O/s
2
Boiler
6.0 kg H2O/s
34 ppm NH3
0.2
kg AN/s
Tail gases
1.2 kg H2O/s
to disposal
Scrubber
18 ppm NH3
4.6 kg AN/s
6.5 kg H2O/s
10 ppm NH3
4.2 kg AN/s
Column
Decanter
Aqueous
layer
25 ppm NH3
0.4 kg AN/s
5.5 kg H2O/s
1 ppm NH3
3.9 kg AN/s
0.3 kg H2O/s
AN to
sales
Bottoms
0 ppm NH3
0.1 kg AN/s
0.7 kg H2O/s
20 ppm NH3
1.1 kg AN/s
12.0 kg H2O/s
16
FW elimination in both scrubber

& boiler ?
Fresh water Water
5.0 kg AN/s
5.1 kg H2O/s
+ Gases
O2
NH3
C3H6
6.0 kg H2O/s
BFW
Steam
1.2 kg H2O/s Boiler
Scrubber
Reactor
Off-Gas
Condensate
14 ppm NH3
0.4 kg AN/s
4.6 kg H2O/s
Condensate
Tail gases
to disposal
18 ppm NH3
4.6 kg AN/s
6.5 kg H2O/s
10 ppm NH3
4.2 kg AN/s
Column
Decanter
Aqueous
layer
25 ppm NH3
0.4 kg AN/s
5.5 kg H2O/s
Fresh water
1 ppm NH3
3.9 kg AN/s
0.3 kg H2O/s
34 ppm NH3
0.2 kg AN/s
1.2 kg H2O/s
AN to
sales
Bottoms
0 ppm NH3
0.1 kg AN/s
0.7 kg H2O/s
20 ppm NH3
1.1 kg AN/s
12.0 kg H2O/s
17
Stream segregation?
Fresh water Water
5.0 kg AN/s
5.1 kg H2O/s
+ Gases
O2
NH3
C3H6
6.0 kg H2O/s
BFW
Steam
1.2 kg H2O/s Boiler
Scrubber
Reactor
Off-Gas
Condensate
14 ppm NH3
0.4 kg AN/s
4.6 kg H2O/s
Condensate
Tail gases
to disposal
18 ppm NH3
4.6 kg AN/s
6.5 kg H2O/s
10 ppm NH3
4.2 kg AN/s
Column
Decanter
Aqueous
layer
25 ppm NH3
0.4 kg AN/s
5.5 kg H2O/s
Fresh water
1 ppm NH3
3.9 kg AN/s
0.3 kg H2O/s
34 ppm NH3
0.2 kg AN/s
1.2 kg H2O/s
AN to
sales
Bottoms
0 ppm NH3
0.1 kg AN/s
0.7 kg H2O/s
20 ppm NH3
1.1 kg AN/s
12.0 kg H2O/s
18
Add a purification unit?

Fresh water Water
5.0 kg AN/s
5.1 kg H2O/s
+ Gases
O2
NH3
C3H6
6.0 kg H2O/s
BFW
Steam
1.2 kg H2O/s Boiler
Scrubber
Reactor
Off-Gas
Condensate
14 ppm NH3
0.4 kg AN/s
4.6 kg H2O/s
Condensate
Tail gases
to disposal
18 ppm NH3
4.6 kg AN/s
6.5 kg H2O/s
10 ppm NH3
4.2 kg AN/s
Column
Decanter
Aqueous
layer
25 ppm NH3
0.4 kg AN/s
5.5 kg H2O/s
Fresh water
Separator
1 ppm NH3
3.9 kg AN/s
0.3 kg H2O/s
34 ppm NH3
0.2 kg AN/s
1.2 kg H2O/s
AN to
sales
Bottoms
0 ppm NH3
0.1 kg AN/s
0.7 kg H2O/s
20 ppm NH3
1.1 kg AN/s
12.0 kg H2O/s
19
Defining separation technologies

Fresh water Water
5.0 kg AN/s
5.1 kg H2O/s
+ Gases
O2
NH3
C3H6
6.0 kg H2O/s
BFW
Steam
1.2 kg H2O/s Boiler
Scrubber
Reactor
Off-Gas
Condensate
14 ppm NH3
0.4 kg AN/s
4.6 kg H2O/s
Ion
Exchange
Condensate
Tail gases
to disposal
18 ppm NH3
4.6 kg AN/s
6.5 kg H2O/s
10 ppm NH3
4.2 kg AN/s
Column
Decanter
Aqueous
layer
25 ppm NH3
0.4 kg AN/s
5.5 kg H2O/s
Fresh water
Extraction
1 ppm NH3
3.9 kg AN/s
0.3 kg H2O/s
34 ppm NH3
0.2 kg AN/s
1.2 kg H2O/s
AN to
sales
Bottoms
0 ppm NH3
0.1 kg AN/s
0.7 kg H2O/s
20 ppm NH3
1.1 kg AN/s
12.0 kg H2O/s
20
Or hybrid separation?
Fresh water Water
5.0 kg AN/s
5.1 kg H2O/s
+ Gases
O2
NH3
C3H6
6.0 kg H2O/s
BFW
Steam
1.2 kg H2O/s Boiler
Scrubber
Reactor
Off-Gas
Condensate
14 ppm NH3
0.4 kg AN/s
4.6 kg H2O/s
Condensate
Tail gases
to disposal
18 ppm NH3
4.6 kg AN/s
6.5 kg H2O/s
10 ppm NH3
4.2 kg AN/s
Column
Decanter
Aqueous
layer
25 ppm NH3
0.4 kg AN/s
5.5 kg H2O/s
Fresh water
Ion
Exchange
Extraction
1 ppm NH3
3.9 kg AN/s
0.3 kg H2O/s
34 ppm NH3
0.2 kg AN/s
1.2 kg H2O/s
AN to
sales
Bottoms
0 ppm NH3
0.1 kg AN/s
0.7 kg H2O/s
20 ppm NH3
1.1 kg AN/s
12.0 kg H2O/s
21
In different order?
Fresh water Water
5.0 kg AN/s
5.1 kg H2O/s
+ Gases
O2
NH3
C3H6
6.0 kg H2O/s
BFW
Steam
1.2 kg H2O/s Boiler
Scrubber
Reactor
Off-Gas
Condensate
14 ppm NH3
0.4 kg AN/s
4.6 kg H2O/s
Condensate
Tail gases
to disposal
18 ppm NH3
4.6 kg AN/s
6.5 kg H2O/s
10 ppm NH3
4.2 kg AN/s
Column
Decanter
Aqueous
layer
25 ppm NH3
0.4 kg AN/s
5.5 kg H2O/s
Fresh water
1 ppm NH3
3.9 kg AN/s
0.3 kg H2O/s
34 ppm NH3
0.2 kg AN/s
1.2 kg H2O/s
AN to
sales
Extraction
Ion
Exchange
Bottoms
0 ppm NH3
0.1 kg AN/s
0.7 kg H2O/s
20 ppm NH3
1.1 kg AN/s
12.0 kg H2O/s
22
The problem statements

Is there any possibility of water reuse in this process?
How to minimise the fresh water usage?
How much wastewater flowrates can be reduced?
Where to place a water purifier?
Is there an optimal
solution???
23
Is there a quickquick-kill solution?
24
Recent advances in pinch analysis

1970s
Synthesis of heat exchanger network (HEN)
1987
Synthesis of HEN for batch processes
1989
Synthesis of mass exchange network (MEN)
1994
Water minimisation (water pinch)
2002
Property integration (property pinch)
2007
Energy planning (carbon pinch)
25
Graphical targeting Material

Recovery Pinch Diagram
(El-Halwagi et al., 2003; Prakash & Shenoy, 2005)
Water reuse/recycle
Current focus
Process 1
Process 1
Process 2
Reuse
Recycle
Process 1
Process 1
Regeneration
Regeneration
Process 2
Process 2
Regeneration-reuse
(Wang & Smith, 1994, 1995)

27
Graphical approach Material

recovery pinch diagram (MRPD)
28
Sink/source representation
Segregated
Source i sources
Source:
Source:AAstream
stream
which
whichcontains
contains
the
thetargeted
targeted
species.
species. Each
Each
source
sourcehas:
has:
Flowrate
FlowrateFFi i
Impurity
Impurity
concentration
concentrationCCi i
Impurity
Impurityload:
load:
mmi ==FFi CCi
i
i i
i=1
i=2
i=3
Sinks j
j=1
j=2
j=3
Sink:
Sink:An
Anexisting
existing
process
processunit/
unit/
equipment
equipmentthat
thatcan
can
accept
acceptaasource.
source.
Each
Eachsink
sinkhas:
has:
Flowrate
FlowrateFFj j
Impurity
Impurity
concentration
concentrationCCj j
where:
where:
CCjmin
min
CCj
CCjmax
max
j
j
j
Load
Loadcapacity:
capacity:
mmi ==FFi CCi
i
i i
(El-Halwagi, 2006)
29
Water sinks & sources for AN case

5.0 kg AN/s
5.1 kg H2O/s
+ Gases
O2
NH3
C3H6
Water
6.0 kg H2O/s
BFW
1.2 kg H2O/s
Scrubber
Reactor
Off-Gas
Condensate
14 ppm NH3
0.4 kg AN/s
4.6 kg H2O/s
Boiler
Steam-jet
Ejector
Condensate
Steam
34 ppm NH3
0.2 kg AN/s
1.2 kg H2O/s
Tail gases
to disposal
18 ppm NH3
4.6 kg AN/s
6.5 kg H2O/s
10 ppm NH3
4.2 kg AN/s
Column
Decanter
Aqueous
layer
25 ppm NH3
0.4 kg AN/s
5.5 kg H2O/s
1 ppm NH3
3.9 kg AN/s
0.3 kg H2O/s
AN to
sales
Bottoms
0 ppm NH3
0.1 kg AN/s
0.7 kg H2O/s
20 ppm NH3
1.1 kg AN/s
12.0 kg H2O/s
Water source ???
30
Water sinks & sources for AN case

5.0 kg AN/s
5.1 kg H2O/s
+ Gases
O2
NH3
C3H6
Water
6.0 kg H2O/s
BFW
1.2 kg H2O/s
Scrubber
Reactor
Off-Gas
Condensate
14 ppm NH3
0.4 kg AN/s
4.6 kg H2O/s
Boiler
Steam-jet
Ejector
Condensate
Steam
34 ppm NH3
0.2 kg AN/s
1.2 kg H2O/s
Tail gases
to disposal
18 ppm NH3
4.6 kg AN/s
6.5 kg H2O/s
10 ppm NH3
4.2 kg AN/s
Column
Decanter
Aqueous
layer
25 ppm NH3
0.4 kg AN/s
5.5 kg H2O/s
1 ppm NH3
3.9 kg AN/s
0.3 kg H2O/s
AN to
sales
Bottoms
0 ppm NH3
0.1 kg AN/s
0.7 kg H2O/s
20 ppm NH3
1.1 kg AN/s
12.0 kg H2O/s
31
Technical constraints
i.
Scrubber
5.8 flowrate of wash feed (kg/s) 6.2
0.0 NH3 content of wash feed (ppm) 10.0
ii. Boiler feed water

NH3 content = 0.0 ppm
AN content = 0.0 ppm
iii. Decanter
10.6 feed flowrate (kg/s) 11.1
Upper bound
Lower bound
Upper bound
iv. Distillation column

5.2 feed flowrate (kg/s) 5.7
0.0 NH3 content of feed (ppm) 30.0
80.0 AN content of feed (wt%) 100.0
Lower bound
32
Limiting water data for AN case

Water sinks, SKj
Flowrate
Concentration
Stream
Fj (kg/s)
Cj (ppm)
Boiler feed water (BFW)
1.2
Scrubber
5.8
10
Flowrate
Concentration
Water sources, SRi

i
Stream
Fi (kg/s)
Ci (ppm)
Distillation bottoms
0.8
Off-gas condensate
5.0
14
Aqueous layer
5.9
25
Ejector condensate
1.4
34
33
Material recovery pinch diagram

Fulfil the following constraints:
Material flowrate
Impurity load
Not limited to water network, other applications include
gas & property network.

Steps required:
Arrange water sinks & sources according to their respective
concentration level in ascending order
Plot flowrate vs. limiting mass load for all water sinks to form sink
composite curve
Plot flowrate vs. limiting mass load for all water sources to form
source composite curve
Shift source composite to the right & below sink composite
34
Sink composite curve

Limiting mass load (mg/s)
300
Sink, SKj
SK1
SK2
j
250
200
Fj (kg/s) Cj (ppm)
1.2
0
5.8
10
7.0
mj (mg/s)
0
58
58
150
100
50
SK2
SK1
5
10
Flowrate (kg/s)
15
35
Source composite curve

300 Source F (kg/s) C (ppm)
i
i
SR1
0.8
0
SR2
5.0
14
250
SR3
5.9
25
SR4
1.4
34
200
13.1
i
mi (mg/s)
0
70.0
147.5
47.6
265.1
SR4
SR3
150
100
SR2
50
SR1
5
10
Flowrate (kg/s)
15
36
Source composite curve

300 Source F (kg/s) C (ppm)
i
i
SR1
0.8
0
SR2
5.0
14
250
SR3
5.9
25
SR4
1.4
34
200
13.1
i
mi (mg/s)
0
70.0
147.5
47.6
265.1
150
100
50
FFW = 2.1
10
Flowrate (kg/s)
FWW = 8.2
15
37
Pure vs. impure fresh source

Impurity load
Impurity load
Sink
composite
Sink
composite
Pinch
point
Pinch
point
Source
composite
Source
composite
Minimum
fresh
Maximum
recycle
Flowrate
Impure fresh
locus
Minimum
waste
Minimum
fresh
Maximum
recycle
Minimum
waste
Flowrate
38
Less & over integration

Impurity load
Impurity load
Sink
composite
Sink
composite
Pinch
point
Infeasible
region
Source
composite
Minimum
fresh
Recycle
Flowrate
Source
composite
Minimum
waste
Fresh
Recycle
Waste
Flowrate
(El-Halwagi, 2006)
39
Significant of the pinch point

The pinch point always located at the pinch causing
source
Some golden rules
Fresh resource can only be used in lower conc. region
Sources above the pinch (including fresh feed) should not
be fed to sink below the pinch, & may not also mix with
sources that are below the pinch concentration.
The pinch causing source is an exception, as part of
it belongs to the region below the pinch.

(Hallale 2002; Manan et al., 2004)
H84PSD
Pinch Analysis
- Process
forSynthesis
Water Recovery
& Design
Lecture 3 - 40
Network design technique

Nearest Neighbour Algorithm (NNA)
(Prakash & Shenoy, 2005a)
Basic principle
To satisfy a sink, the source to be chosen are the
nearest available neighbors to the sink in terms of

impurity concentration.
A source that is just cleaner and a source that is just
dirtier than the sink are mixed to satisfy the sink.
0 ppm
80 ppm
100 ppm
0 ppm
20 ppm
100 ppm
SR1
SR2
SR3
SR1
SR2
SR3
SK1
50 ppm
SK1
50 ppm
42
Basic principle
If the required amount of a source is not available,
then whatever is available of that source is used

completely and the next neighbor source is
considered to satisfy the sink.
100 ton/h
0 ppm
1 ton/h
80 ppm
20 ton/h
100 ppm
SR1
SR2
SR3
SK1
150 t/h
50 ppm
43
Important equations
Assign a pair of neighbours (sources) for the sink:
Neighbour 1 (N1) lower C than the sink
Neighbour 2 (N2) higher C than the sink
Solve the flowrate allocation from source i (i.e. i =
N1 & N2) to sink j:

Overall material balance:
FN1, SKj + FN2, SKj = FSKj

Impurity balance:
FN1, SKj C N1 + FN2, SKj C N2 = FSKj CSKj
44
Main steps for NNA

1. Arrange sinks/sources in increasing order of C, and start
from sink with lowest Cj.
2. Identify source with the same conc. as the sink, i.e. Ci = Cj
to Step 3; else to Step 4.
3. Feed source to the sink when Ci = Cj:
a) If Fi Fj , source is sufficient to satisfy the sink; to Step 2 for the next
sink
b) If Fi Fj , feed the whole source to the sink, to Step 4
4. Identify the pair of neighbours for the sink; determine the

flowrate using Eqs. (1) and (2).
5. Feed source to the sink:
a) If Fi,j the available Fi, the entire sink requirement is met to Step 2
for next sink.
b) If Fi,j the available Fi, use the entire source & solve for next pair of
neighbours.
6. Repeat Steps 2 5 for all sinks.

45
Example (Polley
(Polley & Polley,
Polley, 2000)
Sinks,
SKj
Water flowrate,
Fj (t/h)
Concentration,
C (ppm)
SK1
SK2
SK3
SK4
50
100
80
70
20
50
100
200
Sources,
SRi
Water flowrate,
Fi (t/h)
Concentration,
C (ppm)
SR1
SR2
SR3
SR4
50
100
70
60
50
100
150
250
(Answer: FFW = 70 t/h; FWW = 50 t/h; Cpinch = 150 ppm)

46
Network design with NNA

FW
F = 70 t/h
C = 0 ppm
30 t/h
35 t/h
5 t/h
SK1
SK2
SK3
SK4
F = 50 t/h
C = 20 ppm
m = 1000
F = 100 t/h
C = 50 ppm
m = 5000
F = 80 t/h
C = 100 ppm
m = 8000
F = 70 t/h
C = 200 ppm
m = 14000
20 t/h
30 t/h 35 t/h
65 t/h 10 t/h
35 t/h 35 t/h
SR1
F = 50 t/h
C = 50 ppm
SR2
F = 100 t/h
C = 100 ppm
SR3
F = 70 t/h
C = 150 ppm
25 t/h
SR4
F = 60 t/h
C = 250 ppm
25 t/h
47
Sink/source matching matrix
Fi (t/h) Ci (ppm)
Fj (t/h)
50
100
80
70
Cj (ppm)
20
50
100
200
SK1
SK2
SK3
SK4
SKj
SRi
70
FW
50
50
SR1
100
100
SR2
70
150
SR3
60
250
SR4
50
WW
48
Back to AN case again

Water sinks, SKj
Flowrate
Concentration
Stream
Fj (kg/s)
Cj (ppm)
1.2
Scrubber
5.8
10
Flowrate
Concentration
Water sources, SRi

i
Stream
Fi (kg/s)
Ci (ppm)
0.8
Off-gas condensate
5.0
14
Aqueous layer
5.9
25
Ejector condensate
1.4
34
49

FW
SR1
F = 2.1 kg/s
C = 0 ppm
0.4 kg/s
1.7 kg/s
SK1
SK2
F = 1.2 kg/s
C=0
m=0
F = 5.8 kg/s
C = 10
m = 58
F = 0.8 kg/s
C = 0 ppm
4.1 kg/s
SR2
F = 5.0 kg/s
C = 14 ppm
8.2 kg/s
F = 5.9 kg/s
SR3
C = 25 ppm
SR4
F = 1.4 kg/s
C = 34 ppm
50
Alternative design
FW
SR1
F = 2.1 kg/s
C = 0 ppm
1.2 kg/s
0.9 kg/s
SK1
SK2
F = 1.2 kg/s
C=0
m=0
F = 5.8 kg/s
C = 10
m = 58
F = 0.8 kg/s
C = 0 ppm
4.1 kg/s
SR2
F = 5.0 kg/s
C = 14 ppm
8.2 kg/s
F = 5.9 kg/s
SR3
C = 25 ppm
SR4
F = 1.4 kg/s
C = 34 ppm
51
Network design for reuse/recycle

Fresh water Water
5.0 kg AN/s
5.1 kg H2O/s
+ Gases
O2
NH3
C3H6
6.0 kg H2O/s
BFW
Steam
1.2 kg H2O/s Boiler
Scrubber
Reactor
Off-Gas
Condensate
14 ppm NH3
0.4 kg AN/s
4.6 kg H2O/s
Fresh water
Condensate
Tail gases
to disposal
18 ppm NH3
4.6 kg AN/s
6.5 kg H2O/s
10 ppm NH3
4.2 kg AN/s
Column
Decanter
Aqueous
layer
25 ppm NH3
0.4 kg AN/s
5.5 kg H2O/s
1 ppm NH3
3.9 kg AN/s
0.3 kg H2O/s
34 ppm NH3
0.2 kg AN/s
1.2 kg H2O/s
AN to
sales
Bottoms
0 ppm NH3
0.1 kg AN/s
0.7 kg H2O/s
20 ppm NH3
1.1 kg AN/s
12.0 kg H2O/s
52
Network evolution techniques

(Prakash & Shenoy, 2005b; Ng & Foo, 2006)
Source Shift Algorithm (SSA)

Objective: To simplify a preliminary network
designed by NNA
2 main criteria to consider sink-source candidates:
CSK = CSR
FSK FSR
Main steps:
Identify the sink-source pairs that fulfil both criteria
Feed the sink fully with the source
An equal flowrate of source(s) will be shifted to the sink
that was originally fed by the source
54
A simple example
SK1
F = 100 t/h
C = 100 ppm
FW
F = 50 t/h
C = 0 ppm
SR1
F = 100 t/h
C = 100 ppm
SR2
F = 50 t/h
C = 200 ppm
SK2
F = 100 t/h
C = 100 ppm
(25)
25
(50)
50
25
(25)
SK1
F = 100 t/h
C = 100 ppm
FW
F = 50 t/h
C = 0 ppm
25
50
25
SR1
F = 100 t/h
C = 100 ppm
50
100
SR2
F = 50 t/h
C = 200 ppm
(a)
SK2
F = 100 t/h
C = 100 ppm
50
(b)
55
Another configuration
SK1
F = 100 t/h
C = 100 ppm
FW
F = 50 t/h
C = 0 ppm
SR1
F = 100 t/h
C = 100 ppm
SR2
F = 50 t/h
C = 200 ppm
SK2
F = 100 t/h
C = 100 ppm
(25)
25
(50)
50
25
(25)
SK1
F = 100 t/h
C = 100 ppm
FW
F = 50 t/h
C = 0 ppm
25
50
25
50
SR1
F = 100 t/h
C = 100 ppm
SR2
F = 50 t/h
C = 200 ppm
(a)
SK2
F = 100 t/h
C = 100 ppm
100
50
(b)
56
Example (Polley
(Polley & Polley,
Polley, 2000)
Sinks,
SKj
Water flowrate,
Fj (t/h)
Concentration,
C (ppm)
SK1
SK2
SK3
SK4
50
100
80
70
20
50
100
200
Sources,
SRi
Water flowrate,
Fi (t/h)
Concentration,
C (ppm)
SR1
SR2
SR3
SR4
50
100
70
60
50
100
150
250

57
Identifying sinksink-source pairs
Fi (t/h) Ci (ppm)
Fj (t/h)
50
100
80
70
Cj (ppm)
20
50
100
200
SK1
SK2
SK3
SK4
WW
35
25
35
25
SKj
SRi
70
FW
30
35
50
50
SR1
20
30
100
100
SR2
70
150
SR3
60
250
SR4
35
50
65
10
58
Interconnections: 12 11 10
Fi (t/h) Ci (ppm)
Fj (t/h)
50
100
80
70
Cj (ppm)
20
50
100
200
SK1
SK2
SK3
SK4
WW
55
35
60
25
25
35
25
10
25
50
SKj
SRi
70
FW
30
40
35
50
50
SR1
20
30
100
100
SR2
20
35
15
80
65
70
150
SR3
10
10
60
250
SR4
50
59
Water Path Analysis (WPA)

Definition: a continuous route which starts from a fresh
source, linked with the sink-source connections, and end at a

waste sink.
Objective: Generate alternative networks by adding fresh
resource penalties.
Analogy:
Utility path in removing the smallest heat exchanger unit in HEN
(Linnhoff et al., 1982; Smith, 1995, 2005).
Mass-load path to reduce number of mass exchangers in MEN (ElHalwagi, 1997).
Heuristic: to minimise water penalty, remove the smallest
match among all L-kink connections within all available

water paths.
60
Identifying water paths
Fi (t/h) Ci (ppm)
Fj (t/h)
50
100
80
70
Cj (ppm)
20
50
100
200
SK1
SK2
SK3
SK4
SKj
SRi
70
FW
30
40
50
50
SR1
20
30
100
100
SR2
20
70
150
SR3
10
60
250
SR4
50
WW
80
60
10
50
61
Remove 2 matches with 10 t/h FW
Fi (t/h) Ci (ppm)
Fj (t/h)
50
100
80
70
Cj (ppm)
20
50
100
200
SK1
SK2
SK3
SK4
SKj
SRi
70
FW
30
50
40
50
50
SR1
20
30
100
100
SR2
20
70
150
SR3
10
10
60
250
SR4
50
WW
80
70
60
10
10
60
50
62
Remove 3 matches with 30 t/h FW
Fi (t/h) Ci (ppm)
Fj (t/h)
50
100
80
70
Cj (ppm)
20
50
100
200
SK1
SK2
SK3
SK4
SKj
SRi
70
FW
50
30
50
50
50
SR1
20
20
50
30
100
100
SR2
70
150
SR3
60
250
SR4
20
20
50
WW
20
80
70
60
63
Algebraic approach
Water Cascade Analysis
(Manan et al., 2004; Foo et al., 2006)
Graphical vs. algebraic approaches

Graphical approach
Advantages
Good insights of the
problems
Intuitive
Limitations
Tedious solution for
complex problem
Inaccuracy problems
Scaling problems/
dimensionality
Algebraic Approach
Advantages
Computational effectiveness
Ease for large & complex
problems
Interaction with other softwares,
e.g. process simulators,
spreadsheets
Limitations
Less insight on the problem
65
Concept of material cascading

Without reuse
100 ppm
100 kg/s
Reuse
100 kg/s
(waste)
100 ppm
100 kg/s
100 kg/s
100 kg/s
(fresh source)
200 ppm
200 ppm
50 kg/s
50 kg/s
50 kg/s
(waste)
66
General form
k
Ck
j Fj
i Fi
i Fi j Fj
FC, k
m k Cum. mk FFW, k =
Cum. mk
Ck CFW
FF
k
Ck
(j Fj)1
(i Fi)1
(i Fi j Fj)1
FC, k
k + 1 Ck+1
(j Fj)k+1 (i Fi)k+1 (i Fi j Fj)k+1
Cum. mk+1
FC, k+1
FFW, k+1
mk+1
mn2
FC, n2
n 1 Cn1
n 2 Cn2
mk
Cum. mn1
FFW, n1
Cum. mn
FFW, n
(j Fj)n-2 (i Fi) n-2 (i Fi j Fj)n-2

(j Fj)n-1 (i Fi) n-1 (i Fi j Fj)n-1
FC, n1 = FW mn1
Cn
67
Example of WCA AN production

Water sinks, SKj
Flowrate
Concentration
Stream
Fj (kg/s)
Cj (ppm)
1.2
Scrubber
5.8
10
Flowrate
Concentration
Water sources, SRi

i
Stream
Fi (kg/s)
Ci (ppm)
0.8
Off-gas condensate
5.0
14
Aqueous layer
5.9
25
Ejector condensate
1.4
34
68
Infeasible cascade
k
Ck
(ppm)
j Fj
(kg/s)
i Fi
(kg/s)
i Fi - j Fj
(kg/s)
1.2
0.8
-0.4
10
5.8
FC
(kg/s)
m
(mg/s)
-0.4
-4
-5.8
-6.2
14
25
5.9
34
1.4
1000000
-28.8
-2.06
-42
-1.68
0.3
0.01
6099792.9
6.10
-24.8
-13.2
42.3
1.4
6.1
-0.40
5.9
4.7
-4
5
-1.2
Cum. m
k
Cum. m FFW, k =
Ck CFW
(mg/s)
(kg/s)
6099792.6
69
Feasible cascade
k
Ck
(ppm)
j Fj
(kg/s)
i Fi
(kg/s)
i Fi - j Fj
(kg/s)
FC
(kg/s)
m
(mg/s)
Cum. m
(mg/s)
FFW = 2.06
1
1.2
0.8
-0.4
1.66
10
5.8
-5.8
16.57
-4.14
14
16.57
-16.57
0.00
5
0.86
25
5.9
5.9
34
1.4
60.81
1.4
70.24
FWW = 8.16
8156865.51
1000000
(PINCH)
9.43
6.76
5
9.43
8156935.76
70
Water allocation targets

k
Ck
(ppm)
j Fj
(kg/s)
i Fi
(kg/s)
i Fi - j Fj
(kg/s)
FC
(kg/s)
m
(mg/s)
Cum. m
(mg/s)
FFW = 2.06
Lower
conc.
region
1.2
0.8
-0.4
1.66
10
5.8
-5.8
16.57
-4.14
14
Higher
conc.
region
25
5.9
34
1.4
0.00
(PINCH)
9.43
60.81
1.4
70.24
FWW = 8.16
9.43
5.9
6.76
-16.57
5
0.86
16.57
1000000
8156865.51
8156935.76
Pinch causing source

(Manan et al., 2004)
71
Example (Polley
(Polley & Polley,
Polley, 2000)
Sinks,
SKj
Water flowrate,
Fj (t/h)
Concentration,
C (ppm)
SK1
SK2
SK3
SK4
50
100
80
70
20
50
100
200
Sources,
SRi
Water flowrate,
Fi (t/h)
Concentration,
C (ppm)
SR1
SR2
SR3
SR4
50
100
70
60
50
100
150
250

72
Infeasible cascade
k
Ck
j Fj
i Fi
i Fi - j Fj
FC
Cum. m FF, k =
Cum. mk
C k CF
0
1
20
2
3
4
5
6
7 106
73
Feasible cascade
k
Ck
j Fj
i Fi
i Fi - j Fj
FC
Cum. m
FFW = _______
1
20
2
3
4
5
6
FWW = _______
7 106
74
Targeting for water regeneration

(Ng et al., 2007, 2008)
Water regeneration
Process 1
Process 1
Process 2
Reuse
Current focus
Recycle
Process 1
Process 1
Regeneration
Regeneration
Process 2
Process 2
Regeneration-reuse
(Wang & Smith, 1994, 1995)
76
Water reuse/recycle scheme

Reuse
Process 1
Process 2
WW
FW
Process 3
Recycle
Reuse
FW : fresh water
Process 4
WW : wastewater
77
Water reuse/recycle + regeneration

Mass separating agents
Power/pressure
Regeneration processes
(concentration/pressure driven)
RW
Process 1
Process 2
WW
FW
FW : fresh water
Process 3
WW : wastewater
Process 4
RW : regenerated water
78
Example (Polley & Polley, 2000)

Sinks,
SKj
Water flowrate,
Fj (t/h)
Concentration,
C (ppm)
SK1
SK2
SK3
SK4
50
100
80
70
20
50
100
200
Sources,
SRi
Water flowrate,
Fi (t/h)
Concentration,
C (ppm)
SR1
SR2
SR3
SR4
50
100
70
60
50
100
150
250

79
START
Algorithm
Set regeneration concentration, Cout

Preliminary allocation water sinks/sources are separated
into FWR (Ci ,Cj < Cout) and RWR (Ci ,Cj > Cout)
RWR
jFj > iFi
NO
YES
Sink(s) is shifted to the FWR from lowest Cj until
jFj = iFi in the RWR
Note: FWR fresh water region

RWR regenerated water region
Source(s) is shifted to the FWR from highest
Cj until jFj = iFi in the RWR
All SKj in the FWR with

Cj = 0 ppm?
YES
NO
FRW, FWR is added at Cout in FWR
Additional sink (Fj, A) and source flowrate (Fi, A) are
shifted to the FWR, calculated based on:
Fj Cj = Fi, A (Ci, A Cj, A)
Determine FFW and FWW in FWR
Total FRW = FRW, FWR + FRW, RWR
Ultimate flowrate targets
END
Calculate FRW, FWR = ((Fj Cj)/ CF)
iFi (with Ci higher than

Cout) FRW, FWR
Assumptions:
1. Fixed regen outlet concentration (Cout)
2. Cost of regeneration is omitted
80
Preliminary allocation (Cout = 10 ppm)

k
C
May use both
FW or RW
1
2
j Fj
i Fi
m k
Cum m k
FFW = 70.00
Cout = 10 ppm
20
FC
i Fi i Fj
70
1.4
1.4
50
-50
20
0.6
2
50
100
50
-50
-30
-1.5
0.5
100
150
200
80
100
70
70
20
-10
-0.5
70
60
-70
-10
-0.5
0
(PINCH)
3
2.5
7
11
250
60
106
Total
60
FWW = 50.00
49987.5
49990
300
280
No FW is used here
81
START
RWR
jFj > iFi
NO
YES
Algorithm

Cj = 0 ppm?
YES
NO
Additional sink (Fj, A) and source flowrate (Fi, A)
are shifted to the FWR, calculated based on:

Cout) FRW, FWR
END
82
Reallocation of sink(s) & source(s)

C
0
20
FWR
j F j
i F i
20
50
100
150
Why should we use FW

this source can tolerate
dirty water? Can we
maximise its load?
C
Cout = 10
30
50
100
50
100
80
100
150
200
250
250
106
Total
106
Total
i F i
20
200
20
RWR
j F j
70
70
60
280
280
83
START
RWR
jFj > iFi
NO
YES
Algorithm

Cj = 0 ppm?
YES
NO
Additional sink (Fj, A) and source flowrate (Fi, A)
are shifted to the FWR, calculated based on:
Sink of the
lowest Cj
END

Cout) FRW, FWR
Sources of the lowest Ci &

positive value in the iFi
jFj column of WCT
84
Reallocation of sink(s) & source(s)

C
0
20
FWR
j F j
i F i
20 + 5
50
+5
100
C
Cout = 10
30 5
50
100
50
100
80
100 5
150
200
200
250
250
106
Total
106
Total
i F i
20
150
20 + 5
RWR
j F j
70
70
60
275
275
85
START
RWR
jFj > iFi
NO
YES
Algorithm

Cj = 0 ppm?
YES
NO
Additional sink (Fj, A) and source flowrate (Fi, A) are
shifted to the FWR, calculated based on:

Cout) FRW, FWR
END
86
FW & WW targeting in FWR

k
Ck
(ppm)
j Fj
(t/h)
i Fi
(t/h)
i Fi - j Fj
(t/h)
FC
(t/h)
Cum. m
k
m Cum. m FFW, k =
Ck CFW
(kg/h) (kg/h)
(t/h)
FFW =____
1
20
50
100
25
-25
5
FWW=____
106
Total
25
5
87
FW & WW targeting in FWR

k
Ck
(ppm)
j Fj
(t/h)
i Fi
(t/h)
i Fi - j Fj
(t/h)
FC
(t/h)
m
(kg/h)
Cum. m
(kg/h)
FFW =______
1
0
0.40
20
25
0.40
-25
-0.15
50
0.25
-0.25
100
0.00
5
0.00
106
Total
FWW =_____
25
0.00
88
RW targeting in RWR (infeasible)

k
Ck
(ppm)
j Fj
(t/h)
i Fi
(t/h)
i Fi - j Fj
(t/h)
FC
(t/h)
Cum. mk
m
Cum. m F
=
FW, k
(kg/h)
(kg/h)
(t/h) Ck CRW
FRW = ____
1 Cout = 10
2
20
25
50
100
50
-50
100
80
95
15
150
70
70
200
250
-25
70
-70
60
60
FRW = ____
106
Total
275
275
89
RW targeting in RWR (feasible)

k
Ck
(ppm)
Cout = 10
20
j Fj
(t/h)
i Fi
(t/h)
25
i Fi - j Fj
(t/h)
FC
(t/h)
FRW = ________
m
(kg/h)
53.57
0.54
-25
0.54
28.57
50
100
50
100
80
95
1.39
70
150
0.32
200
70
0.00
60
250
106
Total
3.18
-70
3.18
-6.43
-0.32
70
63.57
-1.07
15
-6.43
0.86
-50
-21.43
Cum. m
(kg/h)
-0.32
60
2.86
FRW = ________
0.54
53560
275
275
90
Nearest neighbour algorithm

Apply NNA (Prakash & Shenoy, 2005) based on the
2 general equations:
Overall material balance:
FN1, SKj + FN2, SKj = FSKj

Impurity balance:
FN1, SKj C N1 + FN2, SKj C N2 = FSKj CSKj

Design separately for FWR & RWR.
91

FW
F = 20
C=0
RW F = 53.57
C = 10
Regeneration
FFW = 20 t/h
FRW = 53.57 t/h
FWW = 0 t/h
20
From FWR
31.25
18.75
3.57
SK1
SK2
SK3
SK4
F = 50 t/h
C = 20
m = 1000
F = 100 t/h
C = 50
m = 5000
F = 80 t/h
C = 100
m = 8000
F = 70
C = 200
m = 14000
From FWR
6.25
F = 50
SR1
C = 50
SR2
F = 100
C = 100
F = 70
SR3
C = 150
43.75
25
70
6.43
6.43
F = 60
SR4
C = 250
53.57
63.57
92
Comparison of various cases

FFW (ton/h)
FWW (ton/h)
Base case
300
280
Reuse/recycle
70
50
Regeneration
20
AN case
FFW (kg/s)
FWW (kg/s)
Base case
7.0
13.1
Reuse/recycle
2.1
8.2
Regeneration*
1.2
7.3
Polley & Polley
* Your own exercise

93
Concluding remarks
Process integration techniques provide a birds eye
view on the maximum extend of water recovery.

Always proceed from options with lower capital
investment/complexity.
Targeting ahead of design!
94
References
El-Halwagi, M. M., Gabriel, F. and Harell, D. (2003). Rigorous Graphical Targeting for Resource Conservation
via Material Recycle/Reuse Networks. Industrial & Engineering Chemistry Research. 42: 4319-4328.
Foo, D. C. Y., Manan, Z. A. and Tan, Y. L. (2006b). Use Cascade Analysis to Optimize Water Networks,
Chemical Engineering Progress. 102(7): 45-52 (July 2006).
Manan, Z. A., Tan, Y. L. and Foo, D. C. Y. (2004). Targeting the Minimum Water Flowrate Using Water
Cascade Analysis Technique AIChE Journal. 50(12): 3169-3183.
Ng, D. K. S. and Foo, D. C. Y. (2006). Evolution of Water Network with Improved Source Shift Algorithm and
Water Path Analysis, Industrial and Engineering Chemistry Research. 45, 8095-8104.
Ng, D. K. S., Foo, D. C. Y. Tan, R. R. and Tan, Y. L. (2007). Ultimate Flowrate Targeting with Regeneration
Placement, Chemical Engineering Research and Design, 85 (A9) 12531267.
Ng, D. K. S., Foo, D. C. Y. and Tan, R. R. (2008). Extension of Targeting Procedure for Ulltmate Flowrate
Targeting with Regeneration Placement by Ng et al., Che. Eng. Res. Des. 85 (A9): 1253 1267. Chemical
Engineering Research and Design, 86(10), 1182-1186.
Polley, G. T. and Polley, H. L. (2000). Design Better Water Networks. Chem Eng Progress. 96(2): 47-52.
Prakash, R. and Shenoy, U. V. (2005a). Targeting and Design of Water Networks for Fixed Flowrate and Fixed
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Dominic C. Y. Foo, PhD, PEng

Dominic.Foo@nottingham.edu.my
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Water Pinch Analysis

Dominic FOO, PhD, PEng

Nottingham Malaysia Campus)

Pinch Analysis for Water Recovery

Pinch Analysis for Water Recovery

Residential water use

Pinch Analysis for Water Recovery

Water usage in our daily life

(5 minutes, 200 Litres)

(3 minutes, 120 Litres)

(Sin Chew Jit Pow, 8 Oct 2003)

Pinch Analysis for Water Recovery

Water usage in our daily life

(10 minutes, 400 Litres)

(15 minutes, 135 Litres)

(2 days once, 130 Litres)

(13.5 Litres / flush)

(Sin Chew Jit Pow, 8 Oct 2003)

Pinch Analysis for Water Recovery

Water use in process plant

Pinch Analysis for Water Recovery

Conventional water network

Pinch Analysis for Water Recovery

Better water utilisation schemes

Pinch Analysis for Water Recovery

Limiting composite curve

Mass transfer-based operation

Pinch Analysis for Water Recovery

Non-mass transfer processes

Reactant & by-product formation

Pinch Analysis for Water Recovery

Pinch Analysis for Water Recovery

Pinch Analysis for Water Recovery

Pinch Analysis for Water Recovery

FW elimination in the boiler?

Pinch Analysis for Water Recovery

FW elimination in both scrubber

Pinch Analysis for Water Recovery

Pinch Analysis for Water Recovery

Add a purification unit?

Pinch Analysis for Water Recovery

Defining separation technologies

Pinch Analysis for Water Recovery

Pinch Analysis for Water Recovery

Pinch Analysis for Water Recovery

The problem statements

Pinch Analysis for Water Recovery

Is there a quickquick-kill solution?

Pinch Analysis for Water Recovery

Recent advances in pinch analysis

Synthesis of heat exchanger network (HEN)

Synthesis of HEN for batch processes

Synthesis of mass exchange network (MEN)

Water minimisation (water pinch)

Property integration (property pinch)

Energy planning (carbon pinch)

Pinch Analysis for Water Recovery

Graphical targeting Material

(Wang & Smith, 1994, 1995)

Graphical approach Material

Pinch Analysis for Water Recovery

Pinch Analysis for Water Recovery

Water sinks & sources for AN case

Water source ???